Headrest assembly

ABSTRACT

A headrest assembly is provided wherein a headrest guide and/or a headrest insert permit adjustment of the headrest even when one or more components of the headrest assembly are misaligned or out of tolerance. The headrest guide includes two sleeves, each sleeve forming a channel, the two sleeves rigidly connected with respect to one another so that the channel of each sleeve is parallel with the other.

CROSS REFERENCE TO RELATED APPLICATION

This application is a divisional of patent application Ser. No.09/435,980, filed on Nov. 8, 1999, now U.S. Pat. No. 6,224,158, issuedon May 1, 2001.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to a headrest assembly including a headrest guideand/or a headrest insert for permitting the sliding movement of avehicle headrest with minimal efforts.

2. Description of Related Art

Automobiles and other vehicles typically include headrests located onthe seatbacks to support and/or brace the head and neck of thepassenger. Headrests are generally adjustable to accommodate passengersof different heights and body types. An important factor inadjustability of the height of headrests are the efforts required tomove the headrest between horizontal positions.

In general, headrests have support rods that are slideably adjustablewithin guides in the seat. If the guides or the support rods aremisaligned, the efforts required to adjust the headrest significantlyincrease. Mori et al., U.S. Pat. No. 5,895,094, and Collier et al., U.S.Pat. No. 4,779,928, are typical of the prior art wherein a rigid crossbar is positioned between support rods within the headrest.

Wallis, U.S. Pat. No. 5,816,658, and Koike, U.S. Pat. No. 5,713,634, aretypical of the prior art having two separate holders or sleeves foraccepting the support rods of the headrest. The separate holders orsleeves are generally positioned within supports welded on to the seatframe. Much of the variability in conventional headrest assembliesresults from the variability in the welded supports on the seat frame.

The above described arrangements may result in misalignment of thesupport rods and/or the holders or sleeves for accepting the supportrods. When such misalignment occurs, the headrest may become difficultto slide with respect to the seat because the centerlines of the supportrods are not aligned with the centerlines of the channels of the holdersor sleeves accepting the support rods.

Therefore, there is a need for one or more individual components withina headrest assembly that permit self-adjusting and/or aligned slidingengagement between headrest rods and the guides for accepting theheadrest rods.

SUMMARY OF THE INVENTION

A headrest assembly according to a preferred embodiment of thisinvention contains one or both of a headrest insert and a headrestguide. Headrest rods preferably extend between the headrest insert andthe headrest guide.

The headrest insert preferably includes two receivers for accommodatingthe headrest rods. Each headrest rod includes a fixed end positionedwithin one receiver and an opposite, moveable end slideably connectedwith respect to the seat, such as within the headrest guide.

The two receivers on the headrest insert are independently moveable withrespect to each other thereby permitting each headrest rod to find itsown center when slideably engaged with respect to the seat. The headrestinsert may comprise a taper, an irregular surface, a reduced thickness,a joint and/or a central transition to facilitate flexibility about acentral area thereby permitting limited independent movement of the tworeceivers with respect to one another.

A headrest guide for accepting two headrest rods may also be used inconnection with the headrest assembly of this invention. The headrestguide comprises two sleeves, each forming a central channel. A pluralityof rigid struts preferably extend between the two sleeves so thatcenterlines of each channel are parallel with respect to one another. Asa result of the struts extending between the sleeves, both sleevesshould always be aligned with respect to one another.

It is one object of this invention to provide a headrest assemblywherein the headrest rods are independently moveable for slidingengagement with misaligned headrest guides.

It is another object of this invention to provide a headrest assemblywherein the headrest guides are connected with respect to each other toprevent misalignment of the headrest guides relative to one another.

It is still another object of this invention to provide a headresthaving an internal headrest insert that permits movement betweenopposite ends of the headrest insert.

It is yet another object of this invention to provide a headrestassembly that permits sliding movement of the headrest rods with respectto the headrest guides with minimal efforts.

BRIEF DESCRIPTION OF THE DRAWINGS

The above-mentioned and other features and objects of this inventionwill be better understood from the following detailed description takenin conjunction with the drawings wherein:

FIG. 1 is a perspective front view of a headrest insert according to onepreferred embodiment of this invention;

FIG. 2 is a top view of the headrest insert shown in FIG. 1;

FIG. 3 is a perspective front view of a headrest insert according to onepreferred embodiment of this invention;

FIG. 4 is a front view of headrest assembly according to one preferredembodiment of this invention;

FIG. 5 is a perspective front view of a guide frame according to onepreferred embodiment of this invention; and

FIG. 6 is a perspective front view of a headrest guide according to onepreferred embodiment of this invention.

DESCRIPTION OF PREFERRED EMBODIMENTS

Headrests are traditionally slideably connected with respect to a seatand typically consist of an inner frame, padding surrounding the frame,and a cover, such as upholstery, around the entire headrest. The innerframe may comprise headrest insert 20, such as shown in FIG. 1 in onepreferred embodiment of this invention.

Headrest insert 20 is preferably at least partially molded from astrong, semi-rigid material such as high density polyethylene (HDPE) orother similar material known to those having ordinary skill in the art.According to one preferred embodiment of this invention, headrest insert20 forms a generally planar, unitary surface. Cost considerations favormolding a unitary headrest insert 20 thereby eliminating the need forthe fitting and assembly of multiple components.

Headrest insert 20 preferably includes two receivers 25. The receivers25 preferably accommodate headrest rods 30. Each headrest rod 30preferably includes fixed end 33 positioned within one receiver 25. Anopposite, moveable end 34 is preferably slideably connected with respectto the seat as described below.

According to a preferred embodiment of this invention, the two receivers25 are independently moveable with respect to each other. Independentmotion of each receiver 25 preferably permits each headrest rod 30 tofind its own center when slideably engaged with respect to the seat.Therefore, if the seat or the headrest is improperly assembled, theheadrest will still slide with minimal efforts with respect to the seat.

As shown in FIGS. 1 and 2, headrest insert 20 may comprise at least onetransition 35, such as a corrugation, bend or similar such irregularsurface molded into an approximate center 38 headrest insert 20. Inaddition, and as further shown in FIGS. 1 and 3, headrest insert 20 maybe tapered between the two receivers 25. Headrest insert 20 may includethe irregular surface at the maximum taper between the two receivers 25.Alternatively, or in addition, headrest insert 20 may further comprise areduced thickness between the two receivers 25. The taper, irregularsurface, reduced thickness and/or transition 35 results in headrestinsert 20 that is flexible about a central area thereby permittinglimited independent movement of the two receivers 25 with respect to oneanother.

According to another preferred embodiment of this invention, headrestinsert 20 further comprises joint 40 positioned between the tworeceivers 25. As shown in FIG. 3, joint 40 may comprise a ball andsocket joint or any other arrangement known to those having ordinaryskill in the art that permits more than one axis of rotation between thetwo receivers 25.

Headrest having headrest insert 20 as described above may be connectedwith respect to a conventional seatback assembly having two independentguides positioned within two welded supports on the seat frame. Headrestinsert 20 will self-adjust in the instance where the welded supports orthe independent guides are misaligned with respect to one another.Alternatively, headrest insert 20 may be used in connection the headrestguide shown in FIGS. 4 and 6.

FIGS. 4 and 6 show headrest guide 50 for accepting two headrest rods 30.Headrest guide 50 preferably comprises two sleeves 55, each sleeve 55forming a central channel 57. The diameter of central channels 57preferably approximately correspond with the diameter of headrest rods30 to permit smooth sliding engagement.

A plurality of rigid struts 60 preferably extend between the two sleeves55 so that centerlines of each channel 57 are parallel with respect toone another. As a result of struts 60 extending between sleeves 55,headrest guide 50 preferably comprises a unitary molded component.Therefore, when one sleeve 55 is misaligned with respect to seat frame70, the other sleeve 55 is correspondingly misaligned resulting insleeves 55 aligning with each other.

According to one preferred embodiment of this invention, as shown inFIGS. 4 and 6, the plurality of rigid struts 60 comprise a firsthorizontal strut 60 positioned between a respective upper region of eachsleeve 55 of the two sleeves 55; a second horizontal strut 60 positionedbetween a respective lower region of each sleeve 55 of the two sleeves55; and two diagonal struts 60 positioned between the upper region andthe lower region of each sleeve 55 of the two sleeves 55. Thisarrangement of struts 60, results in a strong, yet efficient, connectionbetween sleeves 55 in headrest guide 50.

As shown in FIGS. 4 and 5, headrest guide 50 is connected to guide frame75 that is further positioned within seat frame 70. Guide frame 75 iswelded or otherwise affixed with respect to seat frame 70. Guide frame75 preferably includes cavity 80 to permit insertion and/or attachmentof headrest guide 50 to seat frame 70. Headrest guide 50 may be affixedto guide frame. 75 with one or more retaining clips 65 positioned withrespect to an outer surface of the sleeve 55.

Headrest guide 50 may additionally comprise receptacle 63 positioned artwithin a top portion of each sleeve 55 for engaging headrest cap 68.Headrest cap 68 may be configured to permit fixing the horizontalposition of the headrest, such as with a biased latch positioned withinnotches formed in the headrest rods 30.

While in the foregoing specification this invention has been describedin relation to certain preferred embodiments thereof, and many detailshave been set forth for purpose of illustration, it will be apparent tothose skilled in the art that the headrest assembly according to thisinvention is susceptible to additional embodiments and that certain ofthe details described herein can be varied considerably withoutdeparting from the basic principles of the invention.

I claim:
 1. A headrest assembly for connecting a headrest with respectto a seat frame of a vehicle, the headrest assembly comprising: aheadrest guide having two, generally cylindrical sleeves, each of saidsleeves forming a channel, the headrest guide being formed with the twocylindrical sleeves as a single, integrally molded, unitary componentand the two sleeves being rigidly interconnected to each other adjacentupper and lower ends of said sleeves in a fixed parallel relationshipwith respect to one another by a plurality of rigid struts extendingbetween the two sleeves so that the channel of each of said sleeves isparallel with the other; a headrest insert; and two generally parallelrods, each of said rods fixed at one end with respect to the headrestinsert and slidable at an opposite end with respect to one channel inthe headrest guide.
 2. The headrest assembly of claim 1 wherein theheadrest guide is connected with respect to a seat frame of a vehicle.3. The headrest assembly of claim 1 wherein the headrest insert tapersfrom each outer end of the insert toward a center portion of the insert.4. A headrest assembly for connecting a headrest to a seat frame, theheadrest assembly comprising: a headrest guide attached to the seatframe and being formed with two generally cylindrical sleeves as asingle, unitary molded component, said sleeves being rigidlyinterconnected to each other adjacent upper and lower ends of saidsleeves in a fixed parallel relationship with one another by a pluralityof rigid struts extending between the two sleeves, and each of saidsleeves forming a channel wherein a centerline for each of said channelsis parallel with respect to one another; and a headrest insert havingtwo generally parallel rods, each of said rods fixed at one end withrespect to the headrest and slidable at an opposite end with respect tothe associated channel in the sleeves of the headrest guide, whereineach of the two sleeves further includes at least one retaining clippositioned with respect to an outer surface of the sleeve.
 5. A headrestassembly for connecting a headrest to a seat frame, the headrestassembly comprising: a headrest guide attached to the seat frame andbeing formed with two generally cylindrical sleeves as a single, unitarymolded component, said sleeves being rigidly interconnected to eachother adjacent upper and lower ends of said sleeves in a fixed parallelrelationship with one another by a plurality of rigid struts extendingbetween the two sleeves, and each of said sleeves forming a channelwherein a centerline for each of said channels is parallel with respectto one another; and a headrest insert having two generally parallelrods, each of said rods fixed at one end with respect to the headrestand slidable at an opposite end with respect to the associated channelin the sleeves of the headrest guide, wherein each of the two sleevesfurther comprises a receptacle positioned within a top portion of thesleeves, allowing the receptacle for engaging a headrest cap.
 6. Theheadrest assembly of claim 5 wherein the headrest guide is connected toa guide frame that is further positioned within the seat frame.
 7. Theheadrest assembly of claim 4 wherein the headrest guide is connected toa guide frame that is further positioned within the seat frame.
 8. Aheadrest assembly for connecting a headrest to a seat frame, theheadrest assembly comprising: a headrest guide attached to the seatframe and forming a unitary molded component having two sleeves, aplurality of rigid struts extending between the two sleeves, each ofsaid sleeves forming a channel wherein a centerline for each of saidchannels is parallel with respect to one another; and a headrest inserthaving two generally parallel rods, each of said rods fixed at one endwith respect to the headrest insert and slidable at an opposite end withrespect to the associated channel in the sleeves of the headrest guide,wherein the plurality of rigid struts comprise: a first horizontal strutpositioned between a respective upper region of each of the two sleeves;a second horizontal strut positioned between a respective lower regionof each of the two sleeves; and two diagonal struts positioned betweenthe upper region and the lower region of each of the two sleeves.
 9. Aheadrest assembly for connecting a headrest to a seat frame, theheadrest assembly comprising: a headrest guide attached to the seatframe and forming a unitary molded component having two sleeves, aplurality of rigid struts extending between the two sleeves, each ofsaid sleeves forming a channel wherein a centerline for each of saidchannels is parallel with respect to one another; and a headrest inserthaving two generally parallel rods, each of said rods fixed at one endwith respect to the headrest insert and slidable at an opposite end withrespect to the associated channel in the sleeves of the headrest guide,wherein the plurality of rigid struts are integrally molded with respectto the two sleeves.